TECH TORQUE - 1200GSA - engine breather tube relocation on airbox project

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Andyman's picture
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Calling practical tech experts who have done this operation and also our resident Webcrawler experts Corne and Tony.

 

 

 

 

 

 

 

 

 

tHIS IS DUST IN THE 1150 AIR-FILTER BEFORE IT IS FILTERED THROUGH THE MIDDLEtHIS IS DUST IN THE 1150 AIR-FILTER BEFORE IT IS FILTERED THROUGH THE MIDDLE 

 

 

 

 cAME MEN CROSSING THE DOORING RIVERCAMEL MEN CROSSING THE DOORING RIVER

 

The goal

 

 

 

 

 

 create a airbox drain plug at its lowest point (existing drain hole) and to raise the crank case breather up and out of trouble.

 

 

 

 

 

 

 

 

 

 

 

WARNING: below project voids your warranty. Do not try at home without adult supervision.

 

 

 

 

 

Is your engine at risk now

 

 

 

 

 

No this is only for those going alone out far into the cuds and doing deep water crossings and where the possibility of lots of phesh phesh dust and lots water are in your pathway.

 

 

 

 

 

90% of riders can now stop reading. Tony, Corne, you keep on.

 

 

 

 

 

 what your 1200 airbox looks likewhat your 1200 airbox looks like

 

 

 

WHY? What is the problem?

 

 

 

Well the lowest point is actually where the crank breather hose comes straight off the left bank cylinder head- at the cam chain and feeds into the lowest point of the airbox.

 

 

 

Why is this a problem?

 

 

 

If you ingest water during a crossing, by more than 20ml, then it can shake over the bund wall inside the airbox  and gravitate into your cam chain which is the fastest way of been stirred into you oil and ending your ride inside an hour.

 

 

 

Oil in water – oil floats up on top of water – leaving your oil pump immersed in the heavier water. Oil stirred into water by a pump or cam chains turns the oil milky white, reduces oil viscosity toooooo low to lubricate. No lubrication, bearing and metal-on-metal parts wear, heat builds up- catastrophic engine destruction in a couple more hours riding

 

 

 

 

 

 

 

The drain in the airbox direct into your cam chain has never been adequately explained of jusitfied by BMW technicians. They did mould a little plastic box, almost as an afterthought into the corner in the box around the drain hole and put 5mm holes in the top of this ‘trap’.

 

 

 

 

 

 

 

The problem

 

 

 

This little box in the airbox delays you finding out that you did take in water, so its only as you ride and the harmonics of vibration take that water over the box, down the holes and into your oil.

 

 

 

The result if not caught is catastrophic destruction of the lubricating properties of the engine oild and resultant bearing seizure..

 

 

 

I have seen this happen once and goodbye engine.

 

 

 

I have seen this caught as well and ended up towing Wynand 24 kilometres across country to where we could drain the engine and replace the filter and oil twice before we are satisfied we had restored integrity.

 

 

 

 

 

 

 

75% of dual sport bikes never go off road and a small amount go really bush.

 

 

 

But Rony does and Annie I do and so we need to compensate to BM engineering oversight.

 

 

 

 

 

 

 

For cross country riders, this poses a water-in-oil risk problem.

 

 

 

Another longer term cancer is dust in your oil.

 

 

 

 

 

 

 

On really dusty roads, fine dust gets past the filter. This is caught by the oily film on the airbox walls, (oily from crank aspiration of heated oil)

 

 

 

 

 

 

 

When you drop the bike onto its left side the residual oil in the left bank and the crank case gravitates up this crank breather and into the airbox. It collects this oily dust and when you right the bike you now ingest grinding paste into your engine as it all drains back.

 

 

 

The oil that does not get over the little bund wall box lives a mixed life in your airbox.

 

 

 

 

 

 

 

Don’t believe me. Ask the experts.

 

 

 

Ask the two guys who returned from a Namibia tour with engines with bearings badly worn and rattling, one guy was offered a total write-off and got his money, the other got an engine replacement – as they were newish bikes and he sold his bike almost immediately.

 

 

 

 

 

 

 

How will your mod help?

 

 

 

By lifting the crank breather hose (aspirator hose) up higher you can turn the existing airbox outlet into a drain plug and never ingest dusty oil or water into your engine again.

 

 

 

It can be done in a way that is perfectly aesthetic and not noticeable to an untrained eye.

 

 

 

 

 

 

 

Has it been done before?

 

 

 

Yes, many a camel man does this before going trans-Africa or Trans Asia or America.

 

 

 

Some go up high some go midrange.

 

 

 

Our own Camel Man of Wellington, the authentic off-road explorer – Rony, has done a neat mod by routing the crank breather from the lowest point in the airbox to the mid range area of the airbox, out of trouble. However, this brings the pipe outside, exposed and in-your-boot range.

 

 

 

 

 

 

 

Some bikers have routed it up inside of the throttle body to the upper area of the airbox and this is the mod I'm after.

 

 

 

 I’m Looking for:

 

 

 

The right rubber hose to use (which pipe from which car is the best to use as the substitute hose)

 

 

 

Which 90 degree plumbing fitting to use

 

 

 

Which plug to blank the existing stupidly placed hole.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

Andyman's picture
Offline
Joined: 2007/06/22

 I’m Looking for:

 

The right rubber hose to use (which pipe from which car is the best to use as the substitute hose)

 

Which 90 degree plumbing fitting to use

 

Which plug to blank the existing stupidly placed hole.

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

Andyman's picture
Offline
Joined: 2007/06/22

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

Tony's picture
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Joined: 2008/08/24

technical for my little brain.

Suggest you ask someone knowledgeable about hoses - try Hosefit in Paarden Eiland (35 Neptune Street, 510-4299)

A bend in the road is not the end of the road... unless you fail to make the turn. ~Author Unknown

Andyman's picture
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Joined: 2007/06/22

naw Tony, I'm begging you with all your crawler skills to find the dope from theguys who did this on their bikes and then posted somewhere.

I don' wanna reinvent the wheel, I wanna do like he does.

Please go crawling some more, sniff out that blog or site or comment on a forum that deals with this same thing.

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

Offline
Joined: 2007/06/25

Andy if you are getting dust going past the filter element then there is a major problem, be it fitment, lack of servicing or element design. The paper element becomes more efficient as the element becomes contaminated with dust to about 15,0 inches water gauge negative pressure on our bikes. 

A good paper element when new will allow particles of <5 micron to pass through till the first layer of contaminant coats the element.

NEVER blow out a paper element, REPLACE.

Use it, don't use it.

Think before you ink.

Trust is the most valuable asset.

I have the rest of my life to get old.

Andyman's picture
Offline
Joined: 2007/06/22

Rene,

In the last four years I've been looking at and into airboxes when the chance presents itself- simply because I've seen this really fine dust in airboxes.

Riders who do the West Coast andother simil;ar really sandy roasds and ride in the rooster tail of the bike ahead definitely suffer ingress of fine dust into the airbox.

I don't have any in my airbox yet, but on several bikes when clearing fitlers after river crossings I've found this tacky inner wall with a yellow tinged dust film. extremely fine dust.

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

Tony's picture
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Joined: 2008/08/24

A bend in the road is not the end of the road... unless you fail to make the turn. ~Author Unknown

Andyman's picture
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Joined: 2007/06/22

Tony,

I swear by you,

You are THE MAN!!!

This must the 20th time you have crawled a quick answer, Bang on the button for a question.

I am your humble servant and I buy you several drinks when I'm on a ride.

U da Bomb!!

 

This Exactly the mod what I was lookin' for and it is is such clear picto-grammic display any DIY fool can follow it.

Thanks for a Super job!

 

Andyman
Anyone can ride a bike fast....   But can you ride your bike real slow???

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